305834 MORSE GC-40 GCRS-40-40
Contents
1. A 5531 SISSINYVH ONINIM 6 9uoud Tm 5 101 13NVdJ LNSWNYLSNI N33M138 P NDSSISSIN dh 91755 ION NOILOJNNOO 13 005 4 HOLIINNOI 31001 ese w mee 40018 TVNIN2331 3ALLISOd aNNOYY OI 1 WWNINYAL Z 20 avad NO2. r S 7 A lt K OIL DRAIN DANGER OIL FILTER THERMAL VALVE WHILE COMPRESSOR IS RUNNING DO NOTATTEMPT TO DRAIN CONDENSATE REMOVE THE OIL LEVEL FILL PLUG OR BREAK ANY CONNECTION IN THE AIR OR OIL SYSTEM WITHOUT SHUTTING OFF COMPRESSOR AND RELIEVING PRESSURE FROM THE FAILURE TO WITH THIS WARNING CAUSE DAMAGE TO PROPERTY AND SERIOUS BODILY HARM AIR INTAKE FILTER The air intake filter 15 a heavy duty single stage high efficiency filter designed to protect the compressor from dust and foreign objects See compressor mounting system in illustration section Frequency of maintenance of the filter depends on dust conditions at the operating site The filter element must be serviced when clogged maximum pressure drop for proper operation is 15 29 P N 305834 MAINTENANCE AIR OIL COALESCER The air oil coalescer employs an element permanently housed within a spin on canister This is a Single piece unit that requires replacement when it fails to remove the oil from discharge air To replace element P N 302600 proceed as follows Shutdown compressor and wait for complete blow down zero pressure Turn element counterclockwise for removal as viewed from top Install new rubber seal in head and supply a film of fluid directly on the seal Rotat
3. lt E 9 u 91W una pozi P E gt lt 0 06 ul Z S L 8691 LI u 9 tuw 13 P N 305834 Weight 2210 Ibs 1002 Fuel Capacity 50 gal 189 liters ENGINE Model Power 1800 rpm Number of Cylinders Bore and Stroke Displacement Aspiration Battery GENERATOR Model Output kw Voltage Amps COMPRESSOR Model Type Delivery Operating Pressure Range Ambient Operating Temp Range Oil Sump Capacity Total System Capacity Type Cooling System Air Intake Filter Type of Control Air Service Connection 14 P N 305834 SPECIFICATIONS MODEL GCRS 40 40 John Deere 5030TF270 80 hp 60 kw Stand by 72 hp 54 kw Prime 5 3 4 x 4 1 in 86 x 105 mm 186 in 3 05 L Turbo charged 12 650 cca 0 degrees Fahrenheit Meccalte spa Type ECO 32 35 4 40 kw Prime 45 kw Stand by 208 240 3 ph 60 hz 138 208 v 131 220v 120 240v SCI8 Integrated Air Compressor Oil Flooded Rotary Screw 40 1 13 m 80 to150 PSIG 5 5 to 10 3 bar 20 degrees Fahrenheit to 105 degrees Fahrenheit 29 degrees Celsius to 41 degrees Celsius 75 gal 2 63 1 0 3 80 L Oil to Air Single Stage Dry 0 100 Demand 1 2 r S 9 4 8 TOON Y x por bee kri 6 0907 AOI
4. WON 5508 HL GSNH5VW SINI343HL INSET INT TIV SHL 90 6 8 906 XB y CLC 66 9 E NESSISSIN l a p se VL 91 9 HOISINNOTT 29720 90826 Ss ONIZ 43553934 C C C C 010916206 LOE Nd OOSIM G31N3A 19315 43L4VAO 1115 1919 dO 19090 NVIGHNVS 2 1309 ________ 29890 2 ANYAYA sG GOS ALO O dNA9Id 13N3 AN Tila 1803 1303 S OE Y 43 305834 u 5808 JO 163431 10 NI OL 00 A1L93810 NI o Ao aasa 11 OL LON SI ANYWA 0000 NyNa OL LOarans 020 LV 13N3S MOP SLYVd Y 3NISN3 151 LI 219 00000000000 00 00000000 0000 000000000 0000 0000000 00 000 8 L00 0L 0000 OL LOOG 000 9 OL LOO L 000 1 01 0000 LON 15 H 9076 728 906 at Ces NOO SI NIG TY
5. ULX MOTA 090 802096 48 ATINA 8 26 HaHSVMI 11508 9 k 002 0 6866 9 99 Z LX 58 Z l 1692065 9 081 806886 99 180 849 IN 4019806 Vth 042508866 OL vs 99151 21906 L pW 201 _ 002 808826 ES 919 1148 919208 k _ 211 8028926 9 295 SAYMUYVWL AATVA LIINI 98195 66006 140900866 OL ls AVNL OBIIS LIINI 1 ___ 99208 LL ___921 800266 09 X GO vii 520 096 06 14 OL ___002 808626 6b 20999 NAOQAAO18 22810 6 ___09 908626 9P 8 4IOS 931713 1 414414 699608 98 X 9b 8 E GHD MIOOTZIHM 1108 _ 00 9 66 xy 206 8 WWSS X 205 17108 05505606 9 6206 88 6 01 WAS X WINS 205 1109 099 8066266 Sr 3JIVIdS1W33MVINI 4108 28 NINSZ X NINO 60 49 1708 09 01646 AVINL IOBIIS SATIVA LIINI LIASY 4108 L 18 NINOZ X NINO 60 49 1708 00 01466 8105 4108 8 NINOE X 60 49 1109 00 8066 L Z L 849 OOTAN 292 809926 lv 0 NOISVY SV 3 3318 6 2 102102 92 2 91 8 5 849 OOTAN 861 906606 2 3 095 ANAL
6. 9 666 01 00Z i HOLVAINII 81 Y 3NION3 666 60500 amp MOP SIHVA Y 2 1 ul 8691 2 91 L 19 ue IS Sued 4 s 9 4 15 P N 305834 COMPRESSOR OPTION MODEL GCRS 40 40 Your Morse Generator may be eguipped with a belt driven integrated rotary screw compressor COMPRESSORAIR FILTER BLOW DOWN VALVE PRESSURERELIEFVALVE PRESSURE REGULATOR VALVE COALESCER SERVICE VALVE 1 2 FNPT MINIMUM PRESSURE VALVE COMPRESSOR OIL FILL SCIS INTEGRATED THERMAL VALVE ROTARY SCREW OILSIGHTGLASS COMPRESSOROILDRAIN COMPRESSOR This machine 15 a positive displacement air compressor that supplies its rated capacity cfm and its rated pressure psi continuously 100 duty cycle Please see figure above for location of the compressors main components JIN 25 COMPRESSOR 4 AIRPRESSUREGAUGE To use air from this compressor simply connect your airline to 1 2 FNPT ball valve mounted on the discharge end of compressor unit This compressor 15 running when the engine 15 and has an automatic pressure regulating valve that opens and closes the inlet valve depending on airusage 16 P N 305834 COMPRESSOR OPERATION HIGH COMPRESSOR OILTEMPERATURE SHUTDOWN SWITCH COMPRESSOR OIL COOLER CON
7. io ts k S any 455 28 8s 5558585 D 829 52 Sasa HLZ se oe F 55 lt 222438558 m mun Z lt Z oldi Ses Z I ni OS FUEL PICKUP LINE TO NEGATIVE BATTERY POST 48 P N 305834 NV md _ WSHOLN3ANIVS CLCL E6E 1 9 B NESSISSIJN NN 104 SPG NYNLAY OL 1O3rgns 5508 1584 51 NI JHL OL NI 411038410 NI YO 41193414 OL LON SI ANYWA SI LI q3ld OO LON LSNW IVILN 3014 NOO SI ONI SSINLSNGNI 5508 AHL SI NISYSHL NOILVWYOSNI 11 SIHL 00000000000 00 00000000 0000 000000000 0000 0000000 00 000 8 L00 0L 0000 OL 100 S 000501 1001 000 OL 00070 AIG TWNINON S39 VANAS VIS LON AN 49 P N 305834 L Y S 9 CESE MTC Lio Y A 0 000000010 q snaNi 5508 4015343 0000000000 0000 3215 30 A LO WIA WINALL NI YO 1 qasn HOLVAUINID i 380 LLON
8. 5 O 2 On Ap STP E yes 4 j a PA 45 P N 305834 N N 2 9 ad Z EN gt LL s 5 25 v 2 2 A 72 ENGINE PARTS JD5030 40KW GENERATOR 200309 999 MATERIAL Rev Num Rev Datel Released For SEN umama JPC 10 11 2006 SUBJECT TO RETURN UPON PATH DEMAND IS NOT TO BE DIRECTLY IN ANYWAY DE FIDENTIAL AND MUST TRIMENTIAL TO THE IN BEMADE PUBLIC OR TEREST OF BOSS INDUS THIS DRAWING AND ALL INFORMATION THEREIN IS THE PROPERTY OF BOSS INDUSTRIES INC IS CON COPIED IT S LOANED USED DIRECTLY OR IN TRIES INC 010 0000 000000000000000 00 000 0000000 00000 000 0000000 0 00 015 000000000 000 00 020 0 001 amp OVER MACHINED SURFACES 5 001 TO 10 000 4 9 8 0 000 TO 1 000 1 001 5 000 NOMNAL x wk E AO CRA ASA lt QOO q gt GEO 46 P N 305834 930 A Y SSIML L ja a snaNI 5508 30 153431 A JA a AJN 3215 AVMANV NI YO A119339 0 qasn OL LON SI ANYWA 0000 020 SI LI 0314009 LON LSAW SI DNI 5 15 oro 0000000000000 0
9. 010 000 OL 0000 AIG TYNINON 39 VA ANS 60 P N 305834 Q s 0007T01 00 010 1 00110500 1 015 5001 1000 020 10001aoeR MIN 000 000 0000000000 00 0000000000000 0000000000000 0000000000000 CO N YC 4 A N de SS Yj VOORE gt DG Rev N im Kev Late Relea THSDRANNGANDALL LX 0 2 2006 ORMA UNTUNED TERRY BOS UST NOT ENN m VISSI Untano Phone ATSB 1212 Fax 905 824 9406 BEVIADE PUBLIC OR COPIED ITISLOANED SUBJECT TO RETURN U DEMAND IS NOT TO BE USED O OR TRIMENTIAL TO TFE IN TEREST OF BOSSINDUS TRIES INC 61 P N 305834 N 840 kaas 30 r SNGNI 5508 dO 15 3421 KA 66678609 fp SP cn 1215 DD Sit NI ATLITAIG vii 3 LV NI YO ATLO RIIG qasn OL LON SI ANYWA YOLVIIN39 819 N 49 LdO G3NVO 1SI LI d3ld OO NOID SI ONI SSINLSNGNI 9076 728 506 xe4 ZLZL EGE 1p9 ANY SIHL B NESSISSIN e UNN Na peseareg ASE TAN 020 010 00000000000 00 00000000 0000 000000000 0000 0000000 00 000 YAO 1000 0000 OL 1009 000 S OL 1001 000 OL 0000 AIG TVNIWON SI9V
10. 61099 81 L NMOG ANSLLVE 1109 089 021 2 z NMOG 1 9967502 ____ IWAN LUV ALO WALI STS 0509204 L 52 P N 305834 snaNI SSO JO 15 3421 00000000000 000 ON SAG 3ZIS EZ TVIYALVIN Atos aasn 1111100000100 000 Z AJH JOLVIINIOD ESHOLNIJANIS OL LON 5 43408 000 OL 193 020 00001 OL 1009 M Ov 5144 Y TANVd 15 1 7 G3NVO1SI G3IdOO 100 YO JOVI 371111 LON LSNW sl _ NOO SI ONI SSINLSNGNI MO INANON 5508 AHL S35V3 inS CLCL E6E 1 9 9 EI NOILVWHO NI B NESSISSIN 9002 8 1 6 11 SIHL 103 p se l u eieq ASE WAN Oy NR c L X CE OLHGQH QH HOYW MAINIS 091 202126 OEL LO bZ6 08060501 V 029 8 NVI 61206 229 HL NMOHS LON 138 9 8 SSINUVH 9219086 0 OLW 02 LINOHIO 1980906 6 NAD MY0
11. 30VN38 371111 LON LSNW VIIN 3014 006 728 506 CS vers am 9 V 2121 265 279 240Ud NISYSHL oueJuO ESSISSIJA 9002 8 2 9 TW SIHL 103 APU NV 00000000000 00 00000000 0000 0090000000000 0000 00 00000000000 00 000 00000 1000 020 0001 OL 1008 000501 1007 010 0007 OL 000 0 TYNINON S39 ANS 55 P N 305834 yo Il awo f kA es OL WILNAWIML 84 TONI NI YO 47193414 qasn WSHOLN3ANIVS OL LON SI ANYWA Noan OL 193 MMOt SLYVd Y YOLVIGVY SI 31111 Po LON ean any TNE 90 6 k78 G06 4 3 SI DNI SSINLSNGNI MEHI SOME V 6 9 OUBJUO 1 1 9002 8 2 9 SIHL 103 OUT WAN 188 NV 0000000000000 00 0000000000000 00000 00000 00 0000 00 00000000000 00 000 00000 9 000 020 000 0L OL 1009 50 000501 1001 0 0007 OL 00070 AIG TWNINON S39 VANAS G31ONSS3 ND
12. E 5 9 8 DM SNGN 5508 do 15888 1 666 lid SN SHL OL WULNANBIL 3215 SW 30 NI ALO JIA A 00000 43408 10001 GANVO1 SI LI qQ3ldOO 0009011001 0001010000 LON ISNN WILNA 4 0 WO WNIWON NOO SI 5 15 9076 728 506 4 5508 30 AL Od HL STIVANNS GINHIVA 6121 265 179 SUOU d SI NIJXHL NO B neSSISSIJA i NM VG na 104 postopa TIV SHL Aaa GYD 140 709866 v L GHD YIHSVM 290 700866 97 II LX 02 649 17108 001 701626 OL OL X O v 1708 640 701626 9 6 02 7 1 SHD 6 06 y 8 dOl 1139 dynol 2809065 7 341 HY 6209068 9 _____920904 6 00 139 31WId 90906 0 MM09 0t 401 1139 80908 z ocosdr 09 0 dO1 1138 davai 0906 2 JOLVI3IN39 91 908 poo gt Y38 MWNNLe8Vd ALO WLI jS L V 67 305834 P N
13. ap A km Released For DRAWN Missi Ontario DONCTSALE THIS DRAWING AND ALL PRON 44912007 Bs Bsauga UNLESS NOTED INFORMATION T HEREIN IS FHECRED fF Phone 647 393 1212 MACHINED SURE THEPROPERT Y OF BOSS mame oer FIDENTIAL AND MUST NOT BEMADE PUBLIC OR Dots COPIED ITIS LOANED PE 50 4 SUBJECT TORETURN UPON BOX GAUGE BOX HZ VOLT AMP 1 amp OVER RECTLY N ANWAYDE 0000 0000000000 TEREST OF BOSS INDUS D 61118 999 TRIES INC 7 6 5 LA 2 1 73 P N 305834 V G lt E lt gt O n O lt gt SINGLE SETTING 74 P N 305834 1 CONNECTIONS FOR 12 LEAD ALTERNATORS 6 LEAD ALTERNATORS Released For JPC Mississauga Ontario Phone 647 393 1212 TITLE INDUSTRIAL EOUIPMENT ING Fax 905 824 9406 DIAGRAM WIRING GENERATOR 40 amp 60 KW G UNVENTOR531300K TH 2 A DWG REV Kari N 1 rn a 7 a 3215 Hivd NOdN OL LOarans 204 M09 9 JONVO 9076 728 906 XE J 6 279 B NESSISSIA MTT 00 0000000000000 5508 40153431 00 0 zH
14. unn L viL 640 290 700966 4 GHD 1708 001 016 6 9 08 71 SUD OOTAN 47 066 ZL NAD LONG IINVA ____ 92090 N39 dOL T3NVd 0908 HY 8 TANVd 50908 2 9 91 908 NALI 1517 SHBd NZ 69 P N 305834 WV OT El 326 N39 LONG HIV 9076 728 906 2121 562 279 240Ud B NESSISSJA EE HIVd Noan Nuniay OL LII ANS ONI SAML SNGNI 5508 10153431 NI 3HLOL VILNSNRIL 30 AVMANV NI 3410 NI YO ALAA qasn 38O L1ON S GANVOT SILI LON 15 ON V 4 NOO SI ONI SAN 15 5508 30 HL SIN 343HL NO SHL 000000000 0000000 00000 1000 020 00001 OL 1009 0008011001 J 0007 010000 wo UNION S39VI4UNS SST TNT DNA TIOL LON 00 70 305834 0 1 15543 00000
15. 3 39 MOOE E SY OLNI ANI OL LON SI ANYWA Noan OL 193 M Ov SLYVd 15 1 71 SI LI did OD 31111 LON LSNW IVILN m NOD SI ONI SIIYLSNONI at CLZL E6E 2 9 9 9002 8 1 6 TTV ANY SIHL 103 p se l u eieq ASE TAN 188 0000000000000 00 0000000000 000 00000 00000 00 0000 0000000000000 00 000 00000 9 10004 020 0000 OL LOOG 8 000501 1001 010 0007 OL 00070 AIG TWNINON VANAS SS NIHSVM 1 0 700986 Z bl X 0 JAINA AVLS SS 1708 920 86 El 29 X 90 X HIL MSHSVM 90 200246 150 60908 HL TVO3 010908 OL MM09 0t TINVA 1SNI YINOD _ 90090 6 09 9 IINVA ISNI 8908 8 2 JOLVIINI9 8 4908 L ab 02 SdIT1lHd SS LV14 1709 605508 MII 2 LON T3NVd LSNI 0606 20 SSINUVH 19 506 SAN 318VO 434091 ____ 0 9 LIOAZL
16. NV L EN esma 2 A09 SY OLNIAN IO LAN N39 MHOt 1139 90 8 906 X8 2121 262 279 0 ebnessissiy UN Na 103 NOP 00000000000 00 40 1S3YAL 000000000000 NI SHL OL TVILNI3NIAL 00 00000000 0000 NI YO 3810 qasn 0000000 00 000 OL LON SI OL 193 1 00004 OL 1008 SI LI 09 2000801007 LON LSNW NOO SI DNI SSINLSNGNI 0007 OL 00070 5508 40 Sao Vauls GINIMIVA SI NISYSHL 4 410 55 1 SH 9NV 11 SIHL Fivds LON N ZN 68 305834 P N 5508 JO 1538 L NI SHLOL WILNIN L 30 NI NI 1 0000 43408 1000 ozo 00001 OL 1008 SILI 409 000801101 DINA wag A SANNI CAT 9076 8 906 24 SS08 JO sas 6121 265 279 NOLLVWHO4NI TNT 900 701 SH JO y
17. X WWZL 1109 092 212626 28 NINOO X 6 01 YS 1109 001 802626 19 0S _ 87 9 oh zs CV 7 LIINI X 9X 21 8 gogoe lb 2100086 YIDVAS 688908 L OF 13SN39 NdH008L 2 988508 62 0 1497 INO44 2908 82 OA 1 INOYA LNAOW _____ 1249806 6 0 4606 L 9 LASNAD 0081 dHO8 02241 02 ANIDNA 669606 GE 00 3YNASSIYA 00606 ve dWIND ISOH 620 68 706 5 7 1 930 06 ISOH GZO Y8Lv0 ZE oeosar AYNSSAdd 09203 dIQOO I3V 3SOH 800 68 706 LE voar 5 13x0vagl ____ 9020065 02 3A3 8 X 1SOd 87 0 1 GAY LLVE 37870 ____ 981708 L AJY H31dd 1 IN 14420 44 81108 8 144384120490 L 272 MOIS 09 3814 43470H ____ 010 92 MOIS 06 3554 90006 S NMOHS LON 0209 ANOD ANIDNA SSINYVH INVOLHOE vz ONIY O VLAN X SLAW 01708 62 JONVI4 LSAVHXI 1807061 LX dWALYALVM 8400066 Le LX VLIW dW
18. 21 gt Z 100907 13SN39 _ A 8076772506 el W 929 6 696 Ul 2 6 LE L ww gz 298 ul Z L 2 869 ez AL AAA F G ww 0 100260 Ul 8 2 rS 1 129 06 1313 2 13M 8199 0061 31VWIXOHddV 1 13SN39 SAS 1434 666 226002 6 YOLVY3N39 LONG 140 666 99019 L 9 1138 190 666 19049 4 SIHVA Y YO LVIOVS 666 21 002 1 L A3Y HOLVUINII MOP OEOSAF SIHVA Y T13NVd 15 666 2002 1 y LAIN YOLVY3N39 81 Y YOLVYIN39 666 0 002 L 1 1 9 SIHVA 3NION3 666 606007 9 06050 666 802002 YSSWNN 1894 ALO 1511 Se 2299 ul ZIL 1 8 08 aN S 9 L 8 L 15081 4 ul g L LZ W 0621 J Ul ZIL OL 6 38 1 a ww pze u ZIL 96 p 9 ws Z ul b L 8 A TO
19. VIS LON OG N A 56 P N 305834 Fax 905 824 9406 oF 4 O 5 5 2 2 Phone 647 393 1212 RADIATOR amp PARTS JD5030 40KW GENERATOR REV 2 5 2 2 LL 49 0 gt 14 5 2 gt A T E cuss 6 28 2006 7 12 2006 GAINVENTO R531 MATERIAL SUBJECT TO RETURN UPON PATH DIRECTLY IN ANYWAY DE FIDENTIAL AND MUST NOT TRIMENTIAL TO THE IN BEMADE PUBLIC OR TEREST OF BOSS INDUS THIS DRAWING AND ALL INFORMATION THEREIN IS THE PROPERTY OF BOSS INDUSTRIES INC IS CON COPIED IT 15 LOANED DEMAND IS NOT TO BE USED DIRECTLY OR IN TRIES INC 0000 000000000000000 00 010 000 0000000 00000 020 00000000000 00 000000000 000 00 o ul i gi 5 D ul lt 5 001 10 000 0 001 8 da5 qe 1 001 5 000 NOMNAL DM 0 000 TO 1 000 kes 72 O m lt 57 P N 305834 4 3 y 2 1 _6 1 300516 ENGINE OIL FILL Read the operators CI Do ENGINE OIL FILL starting this unit operate Fallure to adhere CHECK DAILY ADD 2 to instructions OIL PER ENGINE without can result in severe MANUAL INSTRUCTIONS personal injury fan guard in
20. Check belt tension Drain water and sediment from fuel tank EVERY 50 HOURS OR WEEKLY Change compressor oil and clean oil filter Check air filter piping fittings and clamps Install new air filter element Shorter interval may be necessary under dusty conditions 4 Check for excessive wear on drive belts Replace if necessary EVERY 500 HOURS OR 6 MONTHS 1 Check safety circuit switches 2 Clean battery terminals 3 Check compressor shaft seal for leakage 4 Install new air filter element Shorter interval may be necessary under dusty conditions 5 Replace spin on coalescer element EVERY 1000 HOURS 1 YEAR 1 Inspect air filter element PERIODICALLY OR 2 Replace spin on coalescer element if necessary AS REQUIRED 3 Inspect and clean compressor oil system cooler etc 4 Check engine and compressor supports NOTE See Maintenance Section for clarification on above 20 P N 305834 COMPRESSOR INSPECTION LUBRICATION AND MAINTENANCE NOTE OBSERVE ALL GAUGE READINGS NOTE ANY CHANGE FROM THE NORMAL READING AND DETERMINE THE CAUSE HAVE NECESSARY REPAIRS MADE NORMAL IS THE USUAL GAUGE READING WHEN OPERATING AT SIMILAR CONDITIONS ONA DAY TO DAY OPERATION FIRST COMPRESSOR OIL AND OIL FILTER CLEANING SHOULD BE DONEAT 50 HOURS ALS0 MORE FREOUENT OIL CHANGES WILL BE REOUIRED UNDER EXTREME OPERATING CONDITIONS OFEXTREMELY HIGH OR LOW TEMPERATURES AND HIGH HUMIDITY CHANGE OIL
21. claim request In case of air ends these will be returned to the manufacturer for their analysis input Send Warranty Claim Service Report request to Morse Industrial Equipment 6990 Cordingley Crescent Mississauga ONTARIO LSN 474 Phone 647 393 1212 Fax 905 824 9406 www morseindustrial ca 35 P N 305834 WARRANTY CLAIMS PREPARATION OFPART RETURN Parts returned to the factory must be properly packaged to prevent damage during shipment Damage to a part as a result of improper handling or packing could be cause for claims disallowance of credit When addressing the package for shipment the following information must be on the outside of or tagged clearly to package Return Goods Authorization number Distributor or end users return address Correct factory address Warranty Claim Service Report number Number of packages pertaining to each claim NOTE Our warranty requires that all defective parts be returned to Morse freight prepaid Items sent without RGA number will not be accepted DAMAGE IN TRANSIT Do not return damaged merchandise to Morse Industrial Inc please follow claim procedure 1 Loss in transit All equipment is tested prior to shipping from our facility Rregardless of the care taken at the factory there is a possibility that damage may occur in shipment For this reason itis recommended that the unit be carefully inspected for evidence of possible damage or malfunction during
22. u OL JNOLVNUILIV gt 5 ES A VC Er 4 z 197218 LA OV 1 3O1O3NNOO 3 2 2 a Es 050 NS GION310S TEHO JALISOd 1 15 3NI9N3 10 NO 1 15 YOLOSNNOO vo 8 EZ J Ling Ea VI OL 3504 LT oz 2 MOIS OS 5 2 3AILISOd 9 019 931915 dy 9 3 VO 9 5 vo 1 S JLIHM Y vl 105 MIA 019 GZ MOLOINNOD 19018 Z ANIONS OL V 01 OF VO vl _ Od ALL m gt 20 gt ONN INA 5 NIN day VS L m w 92 s 5 JNA a Osan INA N z 7 Aa JNN VD L v9 91 3078 vo v aoras Q ama vo yl gt N3349 VD 04 YOLOANNOO 4IMOL gt td E YOLOANNOO NIOLISOd OML ME 2 2 amg va L 5 13 T 3 nas AC u m 031 115 r 20 8 85 818 6 08 8 Z R m 4 ci DN L W 1 2 wyo 50151
23. 4 P N 305834 HAZARDS ELECTRICAL SHOCK HAZARDS This generator produces dangerous electrical voltages that can cause fatal electrical shock Avoid contact with bare wires terminals connections etc while the unit is running Make sure all appropriate covers guards and barriers are in place before operating the generator Do not assume that there 15 not power flow to the terminals connections bare wires etc when the generator Is not running The unit could be connected to another power source that could back feed through the generator wire leads Always test the wire leads for power before working on the unit The National Electrical Code NEC reguires the frame and external electrically conductive parts of the generator to be connected to an approved earth ground unless the generator 15 vehicle mounted See article 250 34 of the NEC handbook if the generator 15 to be mounted in a portable vehicle FIRE HAZARDS For fire safety the generator must be operated and maintained properly Operation must always comply with applicable codes standards laws and regulations Adhere strictly to local state and national electrical and building codes Comply with regulations of the Occupational Safety and Health Administration OSHA Ensure the generator and engine are operated accordance with the manufacturer s instructions and recommendations Do not alter the construction of the generator or engine or change controls which might creat
24. 8 195 W42 OF 140 6665 28609 9 HOLVHSANSS OEOSAF Y HOLVIOVA 666 ZLE00Z 6 0506 SIHVA Y T3NVd 666 115002 HO1VH3N35S 06050 SIHVA Y HO1VH3N3S 666 01 2002 AJH 06060 S Y 666 602002 AJH 9 SILVA Y 666 802002 L NOILdI4353G MIBNNN LHVd 157 SHEd L Ul OL L unu gese 612 H Ul P E PS 2 012 BZ t A LON 978 1 k 21 F 5 T 82591 Ul P E 0902 18 06 41 2 OL ul Z L 85 6 60 1 LG 2 9 u Z L 9 4 U P E 25 1 ul 9 pg Ul pit 16211 dA 1 6 0606 Z L SE 41 P N 305834 5 9 4 E L KSE 508 L 206 41 Viewer ww gese rai 04 LE M 55941 ML L 2758 BS 97281 EE ul __ 296 71 i 0 8 Ul 8 4 6 1 1 29111 15268 12
25. EVERY SIX MONTHS EVEN IF THE NORMAL OIL CHANGE PERIOD IN HOURS HAS NOTYET ELAPSED ALWAYS WARM UP THOROUGHLY PRIOR TO CHANGING EITHER THE ENGINE OIL OR THE COMPRESSOR OIL DO NOT OPEN COMPRESSOR OIL DRAIN OIL FILTER CAP OR OIL FILTER UNTIL ALL PRESSURE HAS BEEN RELIEVED CHECK BY MANUALLY OPENING THE ASME SUMP PRESSURE RELIEF VALVE DRAINING WATER FROM COMPRESSOR OIL Prior to initial start up it is recommended to drain water from the compressor sump Compressor must be shut off for at least 4 6 hours First verify there 15 no pressure in the system Then slowly crack the oil drain cap When opening the oil drain port any water will drain out before the oil if fully separated Catch all fluids in a container and dispose of properly When no water is present retighten the compressor oil drain cap Check the compressor oil level and add oil if necessary 21 P N 305834 LUBRICATION LUBRICANT RECOMMENDATIONS WARNING IT IS IMPORTANT THAT THE COMPRESSOR FLUID BE RECOMMENDED TYPE AND THAT THIS OILAS WELLAS THEAIR FILTER OIL FILTER AND COALESCER ELEMENTS BE INSPECTED AND REPLACED AS STATED IN THIS MANUAL THE COMBINATION OF A SEPARATOR ELEMENT LOADED WITH DIRT AND OXIDIZED OIL PRODUCTS TOGETHER WITH INCREASED AIR VELOCITY ASA RESULT OF THIS CLOGGED CONDITION MAY PRODUCE A CRITICAL POINT WHILE THE MACHINE IS IN OPERATION WHERE IGNITION CAN TAKE PLACE AND COULD CAUSE A FIRE IN THE OIL SUMP FAILURE TO COMPLY WITH THIS
26. If discharge pressure 15 too low check the following a Too much air demand b Service valves open blowing to atmosphere Leaks In service line Restricted compressor inlet atr filter Faulty control system operation regulator Inlet valve etc Low engine speed 2 If discharge pressure is too high or safety valve blows check the following a b C d 28 P N 305834 Oil separator plugged up Faulty safety valve Faulty regulator or set to high Inlet valve leaking or partially open Loss of pressure signal to inlet valve from regulator causing inlet valve to stay open TROUBLESHOOTING BLOWDOWN VALVE If after the compressor is shutdown pressure does not automatically blow down check for 1 Automatic blowdown valve may be inoperative 2 Blockage in air line from compressor to blow down valve 3 Orifice at blowdown clogged ENGINE OVERHEATING Low oil level refill Air blockage into engine fan Air blockage from fan exhaust side of engine Dirty oil in engine Low engine coolant level COMPRESSOR Abnormal compressor consumption or oil in service line check for the following Over filling of oil sump Leaking oil lines or oil cooler Defective separator element Compressor shaft seal leakage Discharge pressure below 55 PSI SEPARATOR PLUGGING If the separator element has to be replaced frequently because 115 plugging up itis an indica
27. Operating and Parts Manual and good engineering practice The total responsibility of Morse for claims losses liabilities or damages whether in contract or tort arising out of or related to its products shall not exceed the purchase price In no event shall Morse be liable for any special indirect incidental or consequential damages of any charter including but not limited to loss of use of productive facilities or equipment loss of profits property damage expenses incurred in reliance on the performance of Morse or lost production whether suffered by Buyer or any third party Morse Industrial Equipment Phone 647 393 1212 6990 Cordingley Crescent Fax 905 824 9406 Mississauga ONTARIO L3N 474 www morseindustrial ca 33 P N 305834 SUMMARY OFMAIN WARRANTY PROVISIONS claims policies and procedure are governed the terms of the Morse Industrial Equipment warranty it is necessary to outline some of more important provisions The Morse warranty applies only to new and unused products which after shipment from the factory have not been altered changed repaired or mistreated in any manner whatsoever Normal maintenance items such as lubricants and filters are not warrantable items Parts not of Morse manufacture are warranted only to the extent they are warranted by the original manufacturer Damage resulting from abuse neglect misapplication or overloading of a machine accessory or part is not covered under w
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29. WARNING MAY CAUSE DAMAGE TO PROPERTY AND SERIOUS BODILY HARM The following general characteristics categorize lubricants that have been found to be satisfactory for use in helical screw type air compressors Due to the impossibility of establishing limits on all physical and chemical properties of lubricants which can affect their performance in the compressor over a broad range of environmental influences the responsibility for recommending and consistently furnishing a suitable heavy duty lubricant must rest with the individual supplier The lubricant supplier s recommendation must therefore be based upon not only the following general characteristics but also upon his own knowledge of the suitability of the recommended lubricant in helical screw type air compressors operating in the particular environment involved CAUTION MIXING DIFFERENT TYPES OF BRANDS OF LUBRICANTS IS NOT RECOMMENDED DUE TO THE POSSIBILITY OF A DILUTION OF THE ADDITIVES OR A REACTION BETWEEN ADDITIVES OF DIFFERENT TYPES 22 P N 305834 LUBRICATION APPLICATION GUIDE Not all lubricating oils are suitable for rotary screw compressor use The most satisfactory oils are the non detergent types that contain high levels of corrosion oxidation and foam inhibitors Your Morse SCI8 compressor is factory filled with Dextron ATF Other non detergent motor oils SAE 10W class SE or CD and HD32 HYD OIL that meet the requirements below can be used Howe
30. the first few hours of operation Responsibility for the safe delivery of the equipment was assumed by the carrier at the time of shipment Therefore claims for loss or damage to the equipment should be made upon the carrier 2 Concealed loss or damage Concealed loss or damage means loss or damage which does not become apparent until the equipment is unpacked or ran by the end user The equipment may be damaged due to rough handling while in route to its destination even though the unit shows no external damage When the damage is discovered upon unpacking make a written request for inspection by the carrier agent within fifteen days of delivery date Then file a claim with the carrier since such damage 15 the carrier s responsibility 36 P N 305834 INDUSTRIAL MORSE INDUSTRIAL EQUIPMENT WARRANTY REGISTRATION Fax Transmission To Warranty Department Fax 905 824 9406 From Date Re Product Registration Pages End User Information Required for Warranty Activation Name Phone Address City State Zip Contact E mail Address Distributor Information Required for Warranty Activation Name Address City State Zip Contact E mail Address Product Information Required for Warranty Activation Model No Serial No Date Product Delivered Compressor Serial No Date Product in Service if units equipped with compressor option ONE REGISTRATION FORM PER UNIT Registration fo
31. voaa 69108 L 6 IVO ZX 31ddlN 00 80126 62 L X L 110 SSS WO Xv ONIHSNB _ 020 209206 8 1198 029 272006 1 9 8 5 GAY 91 0 209206 72 JOLWIND3Y 80008 L 4 ONIZ Z L 3dld 0Z0 0 0906 96 1 G31N3A 2 1 SOIANAS SATIVA 080 0008 P9 E M 43553934 t l 3dld SNIA 10010 91606 9 000 006 07 L CSN 4 544 E 1 __ 72 7 Go 4444 A P N 305834 840 133 8 JO 25 UA 5508 JO 153531 seze e NI HO ALO 3810 qasn 38 OL LON SI HIWd OL 1 3 3111 LON TVI 1N 3d ld SI DNI SSINLSNGNI MOMMA SI NOILVANYOSNI 2 9 900272707 Od TW SIHL B NESSISSIN 1031 ON SMG 9 8105 Nd2 OF LdO N 0000000000000 00 000000000 0000 0090000000000 0000 00 00000000000 00 000 00000 X340 1000 020 000 0L OL 1008 000501 1007
32. will result in forfeiture of claim or c refund the full purchase price for the item without interest Factory installed compressor units will also include warranty on installation for a period of one 1 year This warranty does not cover damage caused by accident misuse or negligence If generator or compressor unit is disassembled the warranty is void Morse s sole responsibility and Buyer s exclusive remedy hereunder is limited to such repair replacement or repayment of the purchase price Parts not of Morse manufacture are warranted only to the extent that they are warranted by the original manufacture Morse shall have no responsibility for any cost or expense incurred by Buyer from inability of Morse to repair under said warranty when such inability is beyond the control of Morse or caused solely by Buyer There are no other warranties express statutory or implied including those of merchantability and of fitness of purpose nor any affirmation of fact or representation which extends beyond the description of the face hereof This warranty shall be void and Morse shall have no responsibility to repair replace or repay the purchase price of defective or damaged parts or components resulting directly or indirectly from the use of repair or replacement parts not of Morse manufacture or approved by Morse or from Buyer s failure to store install maintain and operate the equipment according to the recommendations contained in the
33. 0 1 GHD 1109 81 91 6 MOOT ZIHM LAN 02 GHD OOTAN LAN OL 9 3SOH 1 OL 602 ISOH 1 431009 LNNOW 55032 GNOYHS 971 61 X SLL X X314 ISOH 2 JOLVIIN39 133SN3S 008 22410 INIONI 902 NV V 012 381 NOLVIGVA MNYLA9 3940034 1 3SOH ONINAS 120709856 590700856 940904666 2 00 0 606 2 920 70 626 2 97170866 o 591908 o 209906 22 800906 o 2069906 22 9 4506 22 11569506 o seo 8906 99 66106 0S MNYL ISOH 66106 0S 1000 NYL 66106 0S 42 39 439NNN LAVA cb Lk _ 9 _ Sk _ t t H V _ lt of 6 _ 8 4 pb 9 pb 9 Y LO VI6 V90Z YSEENY dIMLSHSHLVAM 7961086 BL lt 19 Ek ANVL 1 1000 3SOH 6640606 Z z pb j ALO WALI 1511 sued T 2 y 8 54 P N 305834 A OL WILNSWIYL NI dO 119 3414 qasn WSHOLN3ANIVS OL LON SI dNVW3q HLYd Nana OL 1O3rgns 008 SLYVd Y YOLVIGVY Dom i G3NVO1SI LI qd3ld OD
34. 00000 0000 NI SHL OL WILNAWIYL 00000 0000000 0000 Add 3215 30 a NI aasa 20 2070707007000 OL LON SI 3AO 91000 020 00001 OL 1009 GANVO1SI 1031409 0006 9100 LON LSNW TAN SI ONI SSINLSNGNI V 90 6 708 lt 06 5508 40 3HL 5 OUBJUO ebnessissi gt 900 11 01 WATU SIHL SEES TERTS Nal 198 UNN 010 0007 OL 0000 NV 0 NVINYINNIL ___ 060 706196 7 vil GHD 1 14 __ 1240 0986 9 GHD YIHSVM 9290 70086 9 0 7 GHD 1708 001 701666 NSD 1139 130 666 8019 AIA YHOLVYANAS 8105 1420 1401 666 z8609 2 140 8105 1139 ____ peogog L S SAWN Ld WALI SS L 71 P N 305834 Parts List DESCRIPTION ENGINE amp PARTS JD5030 40KW GENERATOR REV 2 FLEX EXHAUST 3 OD X 18 LG SS Y 3 PART NUMBER 1 200309 999 D C N 0 CLAMP EXHAUST 3 A 7 SY Dr AY 2 ET EZ 306036 980100 300 ip a lt SY
35. 0000000 0000 0000000 00 00 00 000000000000 1000 0000101 1008 000 S OL 1007 000 010000 NIG 5508 dO 2121 265 279 SI 1 5 155 9 SIHL y 103 ered roa WAN NV 1SOd JAILISOd OL G31ON SS INN SIINVY3T1OL 37195 LON gt 5 Ze A MO ld NOILO3YI0 NOILVLOY ly 47 P N 305834 REV 2 ENGINE amp PARTS JD5030 40KW GENERATOR FE I gt neis AO li Rev Num Rev Date Released For EN Num Mississauga Ontario Phone 647 393 1212 IMEKS EQUIPMENT 905 824 9406 GAINVENTO 5 MATERIAL IN __ SUBJECT TO RETURN UPON FIDENTIAL AND MUST DIRECTLY IN ANYWAY DE BEMADE PUBLIC OR TEREST OF BOSS INDUS THIS DRAWING AND ALL INFORMATION THEREIN IS THE PROPERTY OF BOSS INDUSTRIES INC IS CON COPIED IT ISLOANED IS TO BE USED DIRECTLY OR IN TRIMENTIAL TO THE IN TRIES INC ORAR YAA A Va 010 015 020 0000 FUEL RETURN LINE lt
36. 05834 WARRANTY SECTION 31 P N 305834 THIS PAGE WAS INTENTIONALLY LEFT BLANK 22 P N 305834 WARRANTY FOR DIESEL ENGINE WARRANTY REFER TO JOHN DEERE MANUAL Morse Industrial Equipment warrants that this generator unit conforms to applicable drawings and specifications approved in writing by Morse The unit assembly will be free from defects in material and workmanship for a period of one 1 year from the date of initial operation or thirty 30 months from the date of shipment whichever period first expires All other components and parts of Morse manufacture will be free from defects in material and workmanship for a period of one 1 year from the date of initial operation or eighteen 18 months from the date of shipment whichever period first expires If within such period Morse receives from the Buyer written notice ofalleged defect in or nonconformance of the unit all other components and parts of Morse manufacture and if in the judgment of Morse these items do not conform are found to be defective in material of workmanship Morse will at its option either a furnish a Service Representative to correct defective workmanship b upon return of the item F O B Morse original shipping point repair or replace the item or issue credit for the replacement item ordered by Buyer Defective material must be returned within thirty 30 days of return shipping instructions from Morse Failure to do so within specified time
37. 2 8126 LYOddNS 497 O 272908 82 92 8 97 6081 le 2 JOLVIINI9 91 608 97 310H M LANN t t X TAMS IIAL MOGTA NWSZ0 r02096 89 er IWS69S0 X TAAS 1 7 1 520 0 096 z 19 M Or 008 0 41 ANIONI GZ 8 L X TAAS SEN 210 70 086 99 ddSd 8 1 3dld 2 2960 L ve 8 1 X 391 2 _ 10 709086 99 819 199 5 93 9849606 8 1 X 5 8 1 _ 210 208026 Z v9 LAIN 8105 OL AATINd 1748 166606 X ddSIN GAH 090 809026 29 15900 0 553 ___ ogigog 9 441 X X 32 1 334 090 808796 29 3TVIN3d HLS N 3 8 1 4 81 331 10 06196 19 ISOH 3 050 68 06 02 8 1 X t i GAY GAH _ 210 709196 09 09204 _ 080 68 706 92 6 8 1 1353315 10 08096 65 09204 350 080 68 706 29 BL LANN t X 910 802096 es YSANOISNSL 1738 5 3SVq 6279706 L
38. 535 430 35 HOJIMS JUNLVUIAAII S OA FUNLVYSdWSL 3NI9N3 5 3NISN3 HOLIMS 06 AL NO 5 gt 9 gt JIO JNIINI MOLIIVAVI qION310S 91 Q 8 03395 3NISN3 gt HOLIMS YOLOSNNOO YALAWLIOA ANAL 1 3YNSSIYA 10 TITIVAVA 9 G3LVIASNI NON day VS OL a Gl yl 2 gt gt gt 00 00 Q gt gt i 0 Z O HOLIMS 110 YOSSIYNdNOO 2ONAJAOI ks GNIONZ NOLOSJNNOO 019 77 305834 P N
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40. 9 9 0 1 7242 44 0944906 8 AJH zoar 062 658 ISNI 88906851 L Z AJY 8820 39NW9 0006 9 262 0 2000628 S VAIN HOLIMS 11006 09 L V 801 8 YLIN 39 ___ 60006 07 VAI OSLLW YNOH 80006 09 z RI 09 LO V 874 8 HOLIMS 200060 NOILdI4953G HIINAN LAVA ALO Z r ZN P N 305834 5 SSO dO 1583941 10 0000 0000 00 000 Wild NI YO qasn OL LON SI ANYWA 0000 21000 9 HLVdl OL 1 5 011005 DEOSOr SLYVd YOLVIGVY gt e G3NVO1 SI LI 0009011001 f f f 31111 LON LSA oro KS _ NOD SI SAINLSNGNI L 90p6 Z8 G06 4 II 9002717 5508 46 AlNadOwd 2121 265 279 SI NISMSHL SSI TNA E NESSISSIA SIHL SaONV ATOL 371795 LON V unn 103 GHD 1915 YSHSVM 949 201 YIHSVM vif X 81 91 6 GHD 1708 L 02 7 649 1708 X
41. AL YSLVM 8 110708 1 8 0906 L 6 8 HATSANW ___ 2490906 Bt _ 012 581 91 0001 MOLVIOSI 794608 1 VIQUIOZ YIADNS ____ 9682206 9 pF 198108 Sk LdNW8 l 81 ____ 758108 L be NMOHS LON 3SOH L 3414 5 3A331S 210 725002 81 dNMOld 1905 1905 AI 91 9 350 __ 160 789006 82 NyYNL38 1909 1909 9 5 350 __ 150 76600 aZ 01 ISOH dAVIO 241008 Ob HAGENS 0951 0008 6 ZIL ISOH LIINI HIY ogz egooog 8 G9 8 49001 19 10 8705 006 071 1 2 _ 15 13759 __ 5918292 9 9 ASSY 37870 812921 S 10 66 lt 6 lt 4 f LSNVHX4S __ 8 9 ONIIJANS HIHSVM 6589 09 Z 2 X VOIL X QO 2 1 ONIGNL 222 Y39WNN Ld ALO NALI x 2 5 V q lt NI 2 q t t P N 305834 4 Mississauga Ontario a Phone 647 393 12 12 oF 6 ENGINE 8 PARTS JD5030 40KW GENERATOR Rev Rev Date Released For EN Num RA WN TI 74 LI THIS DRAWNGANDALL INFORM ATION THEREIN IS
42. C 10 2 2006 MATERIAL SUBJECT TO RETURN UPON PATH DEMAND IS NOT TO BE DIRECTLY IN ANYWAY DE FIDENTIAL AND MUST NOT TRIMENTIAL TO THE IN BEMADE PUBLIC OR TEREST OF BOSS INDUS THIS DRAWING AND ALL INFORMATION THEREIN IS THE PROPERTY OF BOSS INDUSTRIES INC IS CON COPIED IT IS LOANED USED DIRECTLY OR IN TRIES INC 0000 0000 09000000000 00 010 015 000 0000000 00000 020 1 001 TO 5 000 5 001 TO 10 000 0 001 amp OVER 0000000000000 00000000000000 MACHINED SURFACES 4 9 8 NOMNAL DM 0 000 TO 1 000 LT 2 5 824 i A O Ap m lt 64 P N 305834 NV OF 8 Mississauga Ontario Phone 647 393 1212 Fax 905 824 94 06 AIR PRESSURE GAUGE ON INSTRUMENT PANE OPT 40 CFM SCI 8 GENERATOR REV 2 SIZE DWGNO REV ____________ 60982 999 2 K 4 Sy Rev Num Rev Date Released For EN Num CON IDENTIAL AND MUST NOT a SOSEN 2 INDUSTRIES INC Y lt O T O 0 lt z A O a lt LU lt 2 447 LLI u x Y 234 lt gt gt m 505 oz 5 4 o l zo ff e u EA gt N y On
43. ELECTRICAL SHOCK CAN RESULT LOCAL ELECTRICAL CODES MAY REQUIRE THE USE OF AN APPROVED EARTH GROUND TO THE FRAME OF THE GENERATOR THE GENERATOR IS EQUIPPED WITH A MOUNTING GROUND BOLT AND NUT FOR PROPER CONNECTION CONSULT WITH A LOCAL ELECTRICIAN FOR GROUNDING REQUIREMENTS IN YOUR AREA 4 P N 305834 DANGER NEVER ADD FUEL WHILE UNITIS RUNNING DO NOT SMOKE WHEN PUTTING FUEL IN THE TANK DO NOT OVERFILL THE FUEL TANK DIESEL ENGINE EXHAUST CONTAINS DEADLY CARBON MONOXIDE GAS IF BREATHED IN SUFFICIENT CONCENTRATIONS IT CAN CAUSE UNCONSCIOUSNESS OR EVEN DEATH MAKE SURE THE GENERATOR HAS ADAQUETE VENTILATION FOR THE EXHAUST BOTH THE DIESEL ENGINE AND THE GENERATOR REQUIRE FRESH AIR FOR COOLING MAKE SURE SUFFICIENT VENTILATION IS AVAILABLE FOR BOTH THE GENERATOR AND ENGINE FANS OPERATE GENERATOR ON LEVEL SURFACES UP TO OR 10 GRADE DO NOT OPERATE GENERATOR WHERE IT WILL BE EXPOSED TO EXCESSIVE MOISTURE DIRT DUST OR CORROSIVE VAPORS NEVER START OR STOP THE GENERATOR WITH ELECTRICAL LOADS CONNECTED AND THE CONNECTED DEVICES TURNED ON START THE ENGINE FIRST AND LETIT STABILIZE BEFORE TURNING ON THE ELECTRICAL LOADS TURN OFF ALL ELECTRICAL LOADS BEFORE SHUTTING DOWN THE ENGINE 5 P N 305834 6 SAFETY RULES Morse Industrial Equipment Inc recommends that the Installation initial start up and maintenance of this generator 15 carried out by a Morse Generator Dealer Do not attempt to install start wire or
44. IYNS 3199 LON 62 P N 305834 NV 10 47 Es 244 ENS X 28 TAO NS E TU s Fam 4 A Rev Rev Datel Released For JPC 10 2 2006 EN Num Mississauga Ontario Phone 647 393 1212 Fax 905 824 9406 THIS DRAWING AND ALL INFORMATION THEREIN IS THE PROPERTY OF BOSS INDUSTRIES INC IS CON FIDENTIAL AND MUST NOT BEMADE PUBLIC OR COPIED IT IS LOANED 010 015 40 CFM SCI 8 GENERATOR REV 2 SUBJECT TO RETURN UPON PATH DEMAND IS NOT TO BE 0000 MATERIAL USED DIRECTLY OR IN DIRECTLY IN ANYWAY DE TRIMENTIAL TO THE IN TEREST OF BOSS INDUS TRIES INC REV 2 oF 8 1 001 TO 5 000 oj e 5 lt NOMNAL DM 0 000 TO 1 000 63 P N 305834 5 001 TO 10 000 020 0 001 8 OVER 100000000000000 00 000 0000000 00000 0000000000000 000000000 00000 905 824 9406 REV 2 oF 8 5 O O 5 gt Phone 647 393 1212 40 5 8 GENERATOR REV 2 5 2 2 LL 5 gt A 5 2 gt SALE oa JP
45. MORSE GENERATORS MODEL GC 40 amp GCRS 40 40 40 KW OPEN SKID SAFETY MAINTENANCE AND PARTS MANUAL 40 KW PRIME POWER 45 KW STAND BY POWER www morseindustrial ca INDUSTRIAL EQUIPMENT Mississauga Ontario Phone 647 393 1212 Fax 905 824 9406 P N 305834 01 24 2007 NDD SAFETY MAINTENANCE AND PARTS MANUAL MORSE GENERATORS GC 40 TABLE OF CONTENTS Operation amp Maintenance Section PVE OC eet cays E aaa sa 3 ama ki a ala 4 6 Generator IDE nao 7 FAFA AA 9 A 9 Preparacion tor initial UP LLL 10 Normal Staring and StOPPIN 11 Sp u iu 12 15 Model Ia 16 COMpressor a aal a a 17 18 Compressor Inspection Lubrication and 19 27 TOMES OOOO rr 28 30 Compressor Recommended Spare Parts 30 MV TIN e _____ _ 31 36 IS li o I TG 6 Drawing S u u uu uuu aaa E us 39 2 P N 305834 INTRODUCTION Every effort has been expended to make sure that the Information In this manual 15 both accurate and current However Morse Industrial Inc reserves the right to change alter or otherwise improve the product at any time without prior notice Bold printed DANGER boxes point out important safety instructions which 1f not fo
46. N 7 23 v Lo CS ES lt 1 1 0 x 45 O 5 2 Q Phone 647 393 1212 SHEET 1 INDUSTRIAL EQUIPMENT 905 824 9406 2 3 z 2 gt oc 5 lt gt gt jJ o OPT FLEX EXH COUPLER 3 OD X 18 LG G INVENTORS3 60K MATERIAL DE SIZE DWG NO REV Tel 81093 999 TEREST OF BOSS INDUS TRIES INC RAN ass 9 20 2006 THEREIN IS AND ALL ERTY OF BOSS THIS DRAWI INFORMATIO s E 0000000000000 00 000 0000000 0 00 00000 0000 00 0 000 000000 00 HN ED SURFACES DO NOT SCALE TOLERAN CES UNLESS NOTED HI P N 305834 12 V N A NI 4 BASE NEMA1 BOX 3 1 3056960 ____ GROMMIT 1 BOLT 1 4 20 OLATOR 5 16 X 2 12 RUBBER 6 8 1305696 _____ LOC GR55 16 8 305696G 7 HEX GR5 5 16 18 lt N gt Parts List DESCRIPTION BOX NEMA1 W HZ VOLT AMP 40KW COVER NEMA1 BOX 2 2 Qo N m w w gt 2 1 06047 PLATE 40KW GAUGE BOX REV 1 3 1 06824 DIAGRAM WIRING GENERATOR 40 4 60KW GAUGE PANEL lt 12 lt lt a 1 4 Gal ED Gri AP
47. NINON 5508 ALYIAO YA SI9VIYNS GANIHIVN V 21261 265 279 SI NIZY3HL B NESSISSI N TIV SIHL 104 NOU WINN LSAVHX3 dNV1O9 008 00 086 LdNW 8 1 X 210 01096 2 01 45 WAY 1 882 916886 9 NINZL 1 1 YIHSVM 002 216886 z WW9L YIHSVM 096 918886 9 YIHSVM 0SZ Z188 6 PoC 201 002808866 09 110 709886 9 OL 949 1 NIHSVMI 6 0 209826 899 191 YIHSVM 211 802826 X k7rOL HOYW 8 920 209126 ZIL 849 11044 096 808626 2 vil X 81 91 6 GHD ADOTZIHM 17108 9 21 90 626 t NINGE X 60 49 1109 09 91266 8 X 0 GHD 1109 8 0 0 686 NINSS 8849 1109 095 910886 292 806646 81 91 6 MOOT ZIHM LAN 82 202926 27 81 916 GHD OOTAN LAN 991 9067 6 Z 07Z k L GHD DOTAN LAN O L 7Z0Et726 TIVAS SAILISOd AJILLVI HIAOI 8LL90 ANIJHS 1V3H 9MV8H UNS 8 C9090 NOILdI 49534 LYVd ALO 157 Sed N 99 99 _79 59 co _19 __69 es WE 95 3 ES 601
48. OF ENVIRONMENTAL FACTORS SUCHAS THE INTAKE OFREACTIVE GASES OR VAPORS IN THE AIR MAY LEAD TO CHEMICAL CHANGES IN ANY OIL CAUSING PREMATURE FAILURE OF THE LUBRICANT AND THE USEFUL LIFE OF ALL EXTENDED LIFE LUBRICANTS MAY BE SHORTER THAN QUOTED BY THE LUBRICANT SUPPLIER BECAUSE THE NORMAL DRAIN AND REPLACE PERIOD MAY BE EXCEEDED USING SYNTHETIC LUBRICANTS DIFFERING FROM THOSE SPECIFIED IN THIS MANUAL MORSE ENCOURAGES THE USER TO CLOSELY MONITOR THE LUBRICANT CONDITION AND TO PARTICIPATE IN AN OIL ANALYSIS PROGRAM WITH THE SUPPLIER NOTE NO LUBRICANT HOWEVER GOOD AND OR EXPENSIVE CAN REPLACE PROPER MAINTENANCE AND ATTENTION SELECT AND USE IT WISELY ENGINE LUBRICATION Refer to Engine Operator s manual for recommended engine lubricating oil 24 P N 305834 MAINTENANCE COMPRESSOR OIL SUMPFILL LEVEL AND DRAIN Before adding or changing compressor oil make sure that the sump 15 completely relieved of pressure Oil 15 added at the fill cap on side of compressor A drain plug 15 provided at the bottom of the sump The proper oil level when unit is shutdown and has had time to settle 1s at the midpoint of the upper oil sightglass The package must be level when checking the DO NOT OVERFILL The oil sump capacity 15 given in Compressor Specifications OIL FILL UPPER SIGHT GLASS LOWER SIGHT GLASS
49. S HLY Noan Naniad OL LOArans 514 Y YOLVYANAD J 5 pd Y NO9 SI 90 6 8 906 XB y sl 5508 JO 966 9 SI NI3Y3HL NOLLIVAWHOANI EIN SS TNT 11 ONVONMVEO SHL NN im A pp m S aL FL 2 gt ES kasi A RA PR 1 UI 9 ji SU MF lt E 7 oii 9 SS LY14 YIHSVM 1 0 700786 OL ZIL 849 1 1 5 214 902966 GL 8 6 849 LV14 Y3IHSVM 0 9068 6 bl pl 8 5 840 YIHSVM 760 908 56 OZ EL IL X l Z 1 849 1109 C 092 809626 z ZL 91 8 849 1098 002 909626 ZL LL vie X 91 8 840 1104 8 0 008626 8 OL X 91 9 2 GHD 1104 6 4 901626 6 el Z 1 849 OOTAN ___ 292 809526 z 8 91 8 840 ___ 96 905526 4 2 0 0 56 606 9 LISNI9 MA0b 0081 022410209 ____ Wgeggo
50. TROL OR INDICATOR PURPOSE ATR PRESSURE GAUGE Continually monitors the sump pressure at various load and unload conditions COMPRESSOR HIGH DISCHARGE Opens the electrical circuit to shut the machine down TEMPERATURE SHUTDOWN SWITCH when the discharge temperature reaches 240 degrees F Indicates the fluid level in sump Proper level should fill UPPER FLUID LEVEL SIGHTGLASS half the glass Check this level when the machine 1s shutdown URE Vents sump pressure to the atmosphere should pressure Inside sump exceed 217 PSIG Regulates the amount of air mtake m accordance with the amount of compressed atr used Isolates fluid m compressor unit on shutdown COMPRESSOR INLET CONTROL VALVE Senses air pressure signal from sump to provide automatic regulation of the compressor inlet control valve and load controller PRESSURE REGULATING VALVE BLOWDOWN VALVE Vents sump pressure to the atmosphere at shutdown Restricts airflow to balance sump and service air MINIMUM PRESSURE VALVE pressure Assures a minimum of 60 PSIG to the service line 17 P N 305834 COMPRESSOR OPERATION OPERATING CONDITIONS The following conditions should exist for maximum performance of the compressor The compressor should be as close to level as possible when operating The compressor will operate on a 15 degree sideward lengthwise tilt without any adverse problems Fluid carryover and starvatlon may occur 1 operated beyond t
51. UTTON and hold OFF RUN STARTSWITCH GLOW PLUG BY PASS BUTTON Turn the engine OFF RUN START switch to START and hold until engine starts but do not hold any longer than ten seconds at a time Release GLOW PLUG and BYPASS BUTTON after engine has started and run for five to ten seconds Let the engine warm up Once engine 1s warm the generator and compressor are ready for full load operation normal engine temperature is 160 to 190 degrees Fahrenheit NORMAL STOPPING Make sure all electrical devices are turned off Do not turn off the generator while loaded Run generator unloaded for several minutes to allow engine to cool down Turn OFF RUN START switch to the OFF position Inspect and check only if equipped with a compressor Model GCRS 40 40 11 P N 305834 Weight 1900 Ibs 862 Fuel Capacity 50 gal 189 liters ENGINE Model Power 1800 rpm Number of Cylinders Bore and Stroke Displacement Aspiration Battery GENERATOR Model Output kw Voltage Amps 12 P N 305834 SPECIFICATIONS MODEL 40 John Deere 5030TF270 80 hp 60 kw Stand by 72 hp 54 kw Prime 5 3 4 x 4 1 in 86 x 105 mm 186 in 3 05 L Turbo charged 12 v 650 cca O 0 degrees Fahrenheit Meccalte spa Type ECO 32 35 4 40 kw Prime 45 kw Stand by 208 240 3 ph 60 hz 138 208 v 131 220v 120 240v E IS LIKE wasan 216
52. Z MOP EWIUOIIK I IUNK M I W 18 1 1 0621 ul OL 656 262 p ZSL LE 6589 9 28 298 ww 806 p 9 F ul 2865 eo E i ul P E OL 274521 ssaa wa 622 to ul p L 8 tzer F 79 t p L 9 4 E 7014 u 82 1 1 a g 259 66061 ul P E LS fe 2 1 268 129 05 ALIOVdVO 1313 31VWIXOtIddV Z ut y sz 13M 53 866 0022 SLVWIXONddY LH I3AA 31ON i NMOHS LON dWV 11ONZH 140 6668149 135 39 SAS Y 666 222002 97 81 X GO 140 666 6019 L OL 9 78 ww 0606 8125 W390r 1138 140 666 68019 2 6 Ul ZI SE __ 901993435 LONG 1 NII AW0r 1738 140 HO1V213N39 8105 W49 140 2 Y TANVd 1SNI 2 9 SIHVA Y
53. airs Daily visual inspections should become a routine The LUBRICATION AND MAINTENANCE CHART lists serviceable items on this compressor package The items are listed according to their frequency of maintenance followed by those items which need only As Required maintenance The maintenance time intervals are expressed in hours Use the hourmeter readings for determining your maintenance schedules Perform the maintenance at multiple intervals of the hours shown For example when the hourmeter shows 100 on the dial all items listed under EVERY 10 HOURS should be serviced now for the tenth time and all items under EVERY 50 HOURS should be served for the second time In addition to the following LUBRICATION AND MAINTENANCE CHART refer to the Engine Operator s manual for recommended engine lubrication and maintenance DANGER COMPRESSOR MUST BE SHUT DOWN AND COMPLETELY RELIEVED OF PRESSURE PRIOR TO CHECKING FLUID LEVELS OPEN SERVICE VALVE TO ASSURE RELIEF OF SYSTEM AIR PRESSURE FAILURE TO COMPLY WITH THIS WARNING MAY CAUSE DAMAGE TO PROPERTY AND SERIOUS BODILY HARM 19 P N 305834 COMPRESSOR INSPECTION LUBRICATION AND MAINTENANCE CHART INTERVAL ACTION Check compressor and engine level Check air filter Check for oil and air leaks Check fuel supply after running Check for fuel oil and compressor fluid leaks EVERY 10 HOURS OR DAILY Drain water from compressor oil at sump
54. arranty Deterioration or wear occasioned by chemical and or abrasive action or excessive heat shall not constitute defects Parts replacement and or correction of defective workmanship will normally be handled by Morse or their authorized distributor Failure to file a detailed warranty claim service report for each occurrence of material defect of defective workmanship will cause warranty claim to be rejected Defective material must be returned within 30 days of receipt of shipping instructions Failure to do so within specified time will result in forfeiture of claim The distributor is responsible for the initial investigation and write up of the warranty claim Distributor shall be allowed no more than 30 days from date of repair to file a warranty claim service report Warranty for failure of Morse relacement parts covers the net cost of the part only not labor and mileage The Morse warranty does not cover diagnostic calls and travel That is time spent traveling to the machine to analyze the problem and returning with the proper tools and parts to correct the problem Morse will deduct from allowable credits for excess freight caused by sender failing to follow return shipping instructions Distributors or end users automatically deducting the value of a warranty claim from outstanding balances due and payable to Morse prior to receiving written notification of Morse approval of the warranty claim may be subject to forfeiture
55. control to spike and fade thus creating damaging electrical surges Never weld to truck or trailer chassis as this will cause damage to many electrical or electronic components grounded to vehicle chassis 9 P N 305834 PREPARATION FOR INITIAL START UP Every GC 40 and GCRS 40 40 15 tested at the factory before shipment This testing assures that unit 15 operating properly and that the generator and or compressor will deliver 15 rated capacity Regardless of the care taken at the factory there still exists a possibility that damage may occur during shipment For this reason 1 15 recommended that the unit be carefully Inspected for evidence of damage during shipment The unit is shipped with the negative battery cable removed The negative battery cable will need to be connected before starting ASE BATTERY CABLE INSTALLED BATTERY CABLE REMOVED NOTE All wiring connections to the generator should be made by a qualified electrician and inspected to meet all local standards and codes Make sure the unit 15 safe to run before attempting to start 10 P N 305834 NORMAL STARTING Inspect the generator engine compressor and other assemblies for loose connections or damage that might have occurred since the last operation Check engine oil engine fuel compressor oil and anti freeze levels add fluids if necessary If equipped with a compressor close service valves Push in GLOW PLUG and BYPASS B
56. e an unsafe operating condition Keep a fire extinguisher near the generator at all times Make sure the extinguisher 1s rated by the National Fire Protection Association Keep the extinguisher properly charged and be informed on instructions for use EXPLOSION HAZARDS 8 Do not smoke around the generator Wipe any fuel or oil spills immediately Make surethere are no combustible materials near or on the generator that can cause a FIRE or EXPLOSION Keep the area surrounding the generator clean and free from debris P N 305834 WARNING DO NOT START OR STOP GENERATOR WITH ANY CONNECTED ELECTRICAL DEVICE TURNED ON GENERATOR MUST NOT BE STARTED OR STOPPED WITH ANY TYPE OF ELECTRICAL LOAD ON THE GENERATOR LOAD GENERATOR AFTER THE GENERATOR IS WARMED UP Operators must not tamper with engine governed speed High operating speeds are dangerous and increase risk of personal injury or damage to eguipment The generator supplies correct rated freguency and voltage only when running at proper governed speed Incorrect freguency and or voltage can damage some connected electrical loads Only trained service technicians should work on the controll unit ECU Electrical surges and spikes can cause serious damage to your system and everything plugged into it Proper surge protectors should be used between the receptacles and every electrical system being used Improperly tuned engines can force the electronic engine speed
57. e element clockwise by hand until element contact seal as viewed from top Rotate element at edge of can one more turn clockwise with band wrench Run system and check for leaks aot a a tS ES WARNING DO NOT SUBSTITUTE ELEMENT USE ONLY A GENUINE MORSE INDUSTRIAL REPLACEMENT ELEMENT THIS ELEMENT IS RATED AT 200 PSI WORKING PRESSURE USE OF ANY OTHER ELEMENT MAY BE HAZARDOUS AND COULD IMPAIR THE PERFORMANCE AND RELIABILITY OF THE COMPRESSOR POSSIBLY VOIDING THE WARRANTY lt COALESCER REGULATOR VALVE PA 1 2 FNPT SERVICE VALVE EAN MINIMUM PRESSURE VALVE 26 P N 305834 MAINTENANCE OIL FILTER The compressor oil filter 15 a cartridge It1s designed with a built in by pass so that if there 15 a large restriction due to cold oil or clogged element the compressor will still be lubricated To replace filter P N 302601 proceed as follows Make sure system pressure 15 relieved Unscrew with 14mm allen wrench Remove oil filter from housing Remove gasket and clean
58. g L S vie X 02 7 GHD 1104 90 01646 LY 444008 HdE MAOY 6 9606 015 681 87 0001 NOILWY4IA YOLWIOSI 9 50 z ASSY 57870 8 h29g eel ONIGINNS 55891 06 z SINN Led ALLO l __6_ L 4 r IN S 9 305834 P N 50 ssog ISAL 000000000 000 666 NI OL 0090000000000 0000 JAS NI ATLOZ8IO NI HO 41193414 qasn IS Nana OL LO3PANS 020 000 0 OL 1009 0 08 SLYVd Y HOLVAAN 30 15 2 400 0009011001 31 DINA memo V 9190 _ SI DNI 3115 V 9076 768 406 Xe 4 MOE 5508 JO 3HL SS5V33nS GENOVA L 179 900279276 M 1 1 FUN Na 104 ACU ANVasA 01 AWVas LNIVd SAOWSY NV 51 P N 305834 PS hol L 919 snaNI SS 08 do 15 3431 86 01009 3245 E sti NI ATLI34IG IVIYLVA NI YO A 1193910 qasn TATA
59. his tilt NOTE IF THE COMPRESSOR IS BEING USED TO POWER SANDBLASTING EQUIPMENT OR AN AIR TANK USE A CHECK VALVE DIRECTLY AFTER THE SERVICE VALVE TO PREVENT BACK FLOW INTO THE SUMP THIS CHECK VALVE SHOULD HAVE A MAXIMUM PRESSURE DROP RATING OF 2 PSIG 13 78 kPa OPERATING AND A CAPACITY RATING EQUAL TO THE MAXIMUM RATING OF THE COMPRESSOR M ANA NAA AA 4 8 X Wy M XX X X Wy Mi gt gt i M r 18 P N 305834 COMPRESSOR INSPECTION LUBRICATION AND MAINTENANCE This section contains Instructions for performing the Inspection lubrication and maintenance procedures required to keep the compressor in proper operating condition The importance of performing the maintenance described herein cannot be over emphasized Periodic maintenance procedures to be performed on the equipment covered by this manual are listed below It should be understood that the intervals between inspections specified are maximum intervals More frequent inspections should be made if the unit is operating in a dusty environment in high ambient temperature or in other unusual conditions planned program of periodic inspection and maintenance will help avoid premature failure and costly rep
60. llowed could endanger personal safety and or property Read this manual the engine manual and the generator manual thoroughly for both the Diesel Engine and the Generator prior to operating this unit Follow all instructions in all three manuals If you do not understand any portion of the manuals contact your Morse Generator authorized dealer for starting operating and servicing procedures GENERATOR SHOWN WITH COMPRESSOR OPTION ENGINE AIR FILTER ENGINE MUFFLER GENERATOR RADIATOR ENGINE CONTROL PANEL BATTERY AIR COMPRESSOR OPTION P N 305834 SAFETY DANGER IF THIS UNITIS USED FORBACK UPPOWER IN THE EVENT UTILITY POWER FAILURE THE FOLLOWING STEP MUST BE TAKEN BEFORE CONNECTING THE GENERATOR TO AN ELECTRICAL SYSTEM OPEN THE MAIN CIRCUIT BREAKER OR MAIN SWITCH SERVING THE SYSTEM TO ISOLATE THE GENERATOR SYSTEM FROM THE ELECTRIC UTILITY FAILURE TO ISOLATE THE GENERATOR AND UTILITY SYSTEMS MAY RESULT IN DAMAGE TO THE GENERATOR AND MAY ALSO RESULT IN INJURY OR DEATH TO ELECTRIC UTILITY WORKERS DUE TO A BACKFEED OF ELECTRICAL ENERGY DANGER THIS UNIT PRODUCES DANGEROUS HIGH VOLTAGETHAT CAN EXTREMELY HAZARDOUS ELECTRICAL SHOCK AVOID CONTACT WITH BARE WIRES TERMINALS ETC NEVER PERMIT AN UNQUALIFIED PERSON OPERATE SERVICE THIS UNIT NEVER HANDLEANY ELECTRICAL CORDS OR DEVICES WHILESTANDING IN WATER HANDS AND FEET ARE WET HARMFUL FATAL
61. lt gt 5 2 5 Hf OHO 2 2 2 gt gt gt L __ 2 m r 3 2 09 pl lt era E 3 SY E lt Lu 21 E lt O O O OO gt 2203 mE at aw r Z AA 280 E O t ul lt Ta o EQ Br 2 O ra 2 2 Sul n 5 X a x Ee Zo O m lt 65 P N 305834 47 Lo AS gt E A 1 1 E SST 5 w SAY rm N 66 P N 305834 Fax 905 824 9406 REV oF 8 Mississauga Ontario Phone 647 393 1212 6098 2 999 40 SCI 8 GENERATOR REV 2 DW D 2 Date Released For r e F IDENTI AL AND MUST BEMADE PUBLIC OR DIRECTLY IN ANYWAY TRIMENTIAL TOTHE IN TERESTOF BOSS INDUS INFORMATION THEREIN IS T HE PROPERTY BOSS INDUSTRIES INC IS CON COPED ITIS LOANED DEMAND IS NOTTOBE USED DIRECTLY ORIN TRES INC THS DRAWNGAND ALL 00101000 0 010 001T O 5 000 o 9 H 10001 1000 00 000 00 0 00000000 000 00 00 0000000 0000000000000 00
62. of the entire claim 34 P N 305834 WARRANTYINTRODUCTION The warranty policy and procedures outlined here within are detailed to provide the claimant with the Information necessary when filing a warranty claim and enabling Morse the ability to best serve it s customers WARRANTY CLAIMS GENERAL An approved claim depends on the following provision a s A warranty claim service report must be issued by Morse See filing procedures Failed part must be returned within 30 days freight prepaid with receipt of warranty claim service report Part is definitely defective Workmanship is definitely defective Machine is within warranty period Machine has been operating within design conditions Claims made by customers must be verified by distributor prior to contacting Morse WARRANTY CLAIMS FILING PROCEDURES Initiate through purchase order for warranty part or request for credit Warranty Claims Service Report will accompany replacement part When returning failed part to the factory for warranty credit fill out all information requested on Warranty Claims Service Report when it 15 returned to you with replacement part Morse will confirm disposition of failed part within 30 days and or request additional information Claim acceptance or denial will result in release of a credit or confirmation letter of denial Morse will consider each claim on it s own merit and reserves the right to accept or reject
63. or replace the screen Reinsert filter and gasket into housing and tighten with 14mm allen wrench Add re tighten filler cap Check for leaks in operation 17 WARNING DO NOT SUBSTITUTE ELEMENT USE ONLY GENUINE MORSE INDUSTRIAL REPLACEMENT ELEMENT THIS ELEMENT IS RATED AT 200 PSI WORKING PRESSURE USE OF ANY OTHER ELEMENT BE HAZARDOUS AND COULD IMPAIR THE PERFORMANCE AND RELIABILITY OF THE COPRESSOR POSSIBLY VOIDING THE WARRANTY OIL FILL UPPER SIGHT GLASS LOWER SIGHT GLASS y OIL FILTER THERMAL VALVE OIL DRAIN 24 P N 305834 TROUBLESHOOTING UNPLANNED SHUTDOWN When the operation of machine has been interrupted by an unexplained shutdown check the following 1 Check to determine if compressor oil 1s at proper level 2 Check oil cooler for dirt slush ice on the fins or any other obstructions to cooling airflow 3 Make a thorough external check for any cause of shutdown such as broken hose broken oil lines loose or broken wire etc 4 Check the engine oil level with the engine stopped and in a level position If the oil level 15 low remove oil filler cap and fill to the upper limit mark on the dipstick with the recommended oil IMPROPER DISCHARGE PRESSURE
64. perform maintenance on this generator unless you are trained and gualified to do so Personal injury or death may occur Keep hands feet clothing etc away from drive belts fans and other moving parts Never remove drive belts or fan guards while unit 18 running Keep hands and all body parts away from the hot engine exhaust This includes muffler turbo charger and all exhaust pipes Other parts of the engine and radiator are also hot When working on this generator remain alert at all times Wear protective clothing including safety glasses Never work on this equipment when you are mentally or physically fatigued Before performing any maintenance on this equipment disconnect the battery cables to prevent accidental start up Take care not to arc the battery posts do not touch positive to negative with the ends of the cable or tools used to remove the cables Disconnect the negative cable first Reconnect the negative cable last Never wear jewelry when working on this generator Jewelry can conduct electricity resulting in electric shock or may get caught in moving components such as fans or belts causing injury Study the DANGER WARNINGS and SAFETY RULES carefully Become familiar with both the Engine and Generator safety rules and warnings found in their respective manuals Morse Industrial Equipment Inc cannot anticipate every possible circumstance that might involve a safety hazard The warning
65. place DIRECTION OF ROTATION EXHAUST SYSTEM 12 VOLT NEGATIVE GROUND SYSTEM hn U CONNECT NEGATIVE BATTERY TERMINAL GROUND ALLOW SYSTEM TO COOL DOWN MAP Released For DRAWN Mississauga Ontario INFORMATONTHEREINIS CHECK 119 2007 lass Phone 647 393 1212 MACHINE SURFAGES THE PROPERTY OF BOSS Fax 905 824 9406 gt INDUSTRIAL EQUIPMENT ING __ BEMADE PUBLIC OR 1 F C en oe 0 000 15 DECAL 8 INDENT SYS 40KW GENSET DUO 0000 000000000 DEC TL Y IN ANYWAY DE SIZE DWGNO REV 000 000000000 OF 8055 INDUS B 200322 999 TRES 4 3 2 1 58 P N 305834 5508 JO 1 54 51 0000000000 000 noe 666 ae oo NI OL 0000000000000 0000 30 AVMANW NI aasa HO9EGUOLNJAN KO OL LON 51 00000 340 1000 8 19S WHO OF 140 2 ONIZ 3883938 8 3dld ONId 00 61606 ve al 1540891 1V9 8 1 AAO813 00 618106 5 V ZLZ1 868 Zr9 hi 1 9 2 1331 3dld AAO813 020 911106 ze v 15 1 5 ASHOW 1 010908 LE MA 09 9 LSNI 8223081 L 0
66. rm must be mailed or faxed within 15 days of customer installation Mail to Morse Industrial Equipment Warranty Department 6990 Cordingley Cresent Mississauga Ontario L 5N 424 Phone 657 393 1212 Fax 905 824 9406 Warranty Registration Rev 10 31 06 37 P N 305834 THIS PAGE WAS INTENTIONALLY LEFT BLANK 36 P N 305834 ILLUSTRATION DRAWINGS 39 P N 305834 THIS PAGE WAS INTENTIONALLY LEFT BLANK 40 P N 305834 x ki wasi 2 1 cas kt Z PD Lili 9281 uw zear 4 6556 LE 298 EE z 865 ul Z L EZ 7 262 bb 8061 JOYWHOSIO 1 52681 189 05 13043 2 8661 0022 ILWWIXOYAdY LHOIZM 1 INMOHS LON X08 LdO zL 135N39 SAS 1434 939 666 22200 LI 97 81 X QO 140 666 6019 OL 8195 W390 1138 140 6656 68019 6 HOLVAINIS LON 140 666 88019 8 1 138 N39 1139 140 666 8019 i 2 HOLWHANSD
67. s In this manual and also the engine and generator manuals are not all inclusive and one must use common sense to satisfy oneself that this equipment is safe for you and others to operate and or service P N 305834 GENERATOR DESCRIPTION This generator 15 a frame mounted diesel engine driven revolving field alternating current generator The generators revolving field 15 driven at 1800 rpm by the diesel engine the diesel engine speed is controlled by an electronic governor Please refer to the John Deere Engine Operator s Manual for more information on the electronic governor or engine control unit ECU ELECTRONIC GOVERNOR ECU This generator can be used for prime or stand by power and can be wired 3 phase or 1 phase at a frequency of 60 hertz Voltage can be 120 240 1 PH or 208 to 240 and 416 to 480 volt 3 PH Please refer to the Generator Manual for details Follow all local electrical codes that may require proper grounding of the generator and its electrical system In case of an accident caused by electric shock immedlately shut down the generator Move the rotary OFF RUN START switch on the control panel to the OFF position Do not try to free the victim with the generator running the electric shock could pass from the victim to anyone in contact with the victim Make sure the generator 15 off and the electric system 15 de energized Seek medical attention immediately OFF RUN STARTSWITCH
68. tion that foreign material may be entering the compressor inlet or the compressor oil Is breaking down or excessive moisture Is not being drawn from the unit Compressor oil can break down prematurely for a number of reasons 1 Extreme operating temperature 2 Negligence in draining condensate from oil sump 3 Using the improper type of oil 4 Dirty oil The complete inlet system should be checked for leaks 29 P N 305834 TROUBLESHOOTING HIGH COMPRESSOR DISCHARGE TEMPERATURE Check compressor oil level Add oil if required see section for oil specifications Check engine fan and fan belt Clean outside of oil cooler Clean oil system cooler internally Plugged compressor oil filter Change element Plugged oil return line clean orifice and check valve sh ad a INSUFFICIENT AIR DELIVERY 1 Plugged compressor air filter clean or replace 2 Plugged air oil separator Replace separator element and also change compressor oil and oil filter at this time Defective pressure regulator adjust or repair 4 Engine speed too low readjust engine speed 2 COMPRESSOR RECOMMENDED SPARE PARTS Below you will find a list of parts we recommend you keep on hand for your compressor option The parts can be orderded under kit P N 61095 OUANITY DESCRIPTION PART NUMBER AIR FILTER ELEMENT 302091 OIL FILTER ELEMENT 302601 COALESCER SPIN ON 302600 SHAFT SEAL REPAIR KIT 302193 DRIVE BELTS 30 P N 3
69. ver Morse recommends you use Dextron III ATF The viscosity of the chosen depends largely on the ambient operating temperature range The oil must provide sufficient lubrication for bearings and rotors at operating temperature and it must have a pour point low enough to provide fluidity at low starting temperatures In general the viscosity range represented by these SAE grades is satisfactory for the temperature range shown 20 degrees Fahrenheit to 120 degrees Fahrenheit HD 32 HYD OIL 25 degrees Fahrenheit Pour Point 10 degrees Fahrenheit to 75 degrees Fahrenheit SAE 10 W 20 degrees Fahrenheit Pour Point 40 degrees Fahrenheit to 120 degrees Fahrenheit Auto Trans Fluid 50 degrees Fahrenheit Pour Point PRIME LUBRICANT CHARACTERISTICS 1 Flash point 400 degrees F minimum ASTM D 92 COC 2 Pour point must be at least 20 degrees F lower than the lowest expected ambient temperature 3 Contain rust and oxidation inhibitors 4 Contain foam suppressors SYNTHETIC DIESTER AND SYNTHESIZED HYDROCARBON LUBRICANTS OIL All elastomeric components and all metal used in the compressor are fully compatible with synthetic diester and synthesized hydrocarbon lubricants The viscosity grade chosen for synthetic diester base or SHC lubricants should be based upon the suggested viscosity ranges listed under prime lubricant characteristics and the lubricant supplier 23 P N 305834 LUBRICATION NOTE UNKNOWN INFLUENCES
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